Container forming machine



J. W. SCULLY CONTAINER FORMING MACHINE Jan. 27, 1970 Filed Dec. 17, 1965 4 Sheets-Sheet 1 INVENTOR. 93 John W. Scu/ly Lg mwdmm ATTORNEY Jan. 27, 1970 J. w. SCULLY CONTAINER FORMING MACHINE INVENTOR. John W. Scu/ly .4 Sheets-Sheet 2 BY fl wed ATTORNEY Filed Dec. 17, 1965' .4 Sheets-Sheet 3 Filed Dec. 17, 1965 INVENTOR. John W \Scul/y BY wmm wmm

ATTORNEY Jan. 27, 1970 J. w. SCULLY 3,492,189

CONTAINER FORMING MACHINE Filed Dec. 17, 1965 .4 Sheets-Sheet 4 INVENTOR. John W. Scu/ly BY WM! CLMJ Q ATTORNEY United States Patent 3,492,189 CONTAINER FORMING MACHINE John W. Scully, Raynham, Mass., assignor to Pneumatic Scale Corporation, Quincy, Mass., a corporation of Massachusetts Filed Dec. 17, 1965, Ser. No. 514,566 Int. Cl. B32]: 31/04 US. Cl. l56519 7 Claims ABSTRACT OF THE DISCLOSURE A container forining machine having provision for feeding and intermittently advancing successive lengths of a web of flexible sheet material into operative position to be wrapped about a forming block to produce a container wherein provision is made for combining with said successive lengths a sheet of stiffening material.

This invention relates to a container forming machine and more particularly to web feeding appartus for a container forming machine.

The invention has for an object to provide a novel and improved container forming machine wherein a web of flexible sheet material is utilized to produce successive containers and which is characterized by novel provision for combining with successive container forming sections of the web a sheet of cardboard to serve as a stiffener for the subsequently formed container.

The invention has for a further object to provide a novel and improved container forming machine wherein a printed web of flexible sheet material is advanced into operative position to be wrapped about a forming block and wherein provision is made for controlling the feeding of the web to effect registration of successive printed sections of the web with relation to the forming block and which is characterized by novel mechanism for combining with successive printed container forming sections of the web a sheet of stiffening material arranged to be wrapped with the flexible sheet material about the forming block to produce a container.

With these general objects in view and such others as may hereinafter appear, the invention consists in the container forming machine and in the various structures, arrangements and combinations of parts hereinafter described and particularly defined in the claims at the end of this specification.

In the drawings illustrating the preferred embodiment of the invention:

FIG. 1 is a side elevation of a container forming machine embodying the present invention;

FIG. 2 is a plan view of FIG. 1;

FIG. 3 is an enlarged detail view in a side elevation of a portion of the apparatus shown in FIG. 1;

FIG. 4 is a plan view of a blank of flexible sheet material showing a sheet of stiffening material combined therewith;

FIG. 5 is a perspective view of a container produced from the blank shown in FIG. 4, some of the parts being broken away; and

FIG. 6 is a side elevation of the flexible web withdrawing mechanism as seen from the side opposite that shown in FIG. 1.

In general, the present invention contemplates novel web feeding apparatus for a container forming machine for feeding a web of flexible sheet material from a supply thereof and for combining with successive container form ing sections of the web a sheet of stiffening material, such as a sheet of cardboard, the web with its sheet of cardboard secured thereto being advanced into operative position to be severed to produce successive individual sheets 'ice of container forming blanks. The invention is herein illustrated as embodied in a container forming machine wherein the blanks are fed into operative position to be Wrapped about a forming block to form a container. Inasmuch as the details of such container forming machines are well known and of themselves constitute no part of the present invention, only suflicient portions of such machines are herein illustrated and described to enable the present invention to be understood In the illustrated embodiment of the invention, the flexible container forming material comprises a printed web of sheet material, and provision is made for controlling the feed of the web by varying the linear advance in response to means for detecting the position of successive printed container forming sections at a predetermined time in each cycle of operation whereby to compensate for any variations in the lengths of the printed sections of the web so as to assure registration of successive container forming sections with the container forming instrumentalities. Prior to the present invention, it has been the practice to attach the stiffening material to individual printed sheets of container forming material which were individually fed into the machine to be wrapped about successive forming blocks.

In accordance with the present invention, successive sheets of stiffening material are combined with the web of flexible container forming material in registered relation to successive printed container forming sections to be advanced into operative position to successive forming blocks and severed to form individual composite blanks which are wrapped about the forming blocks to produce flexible containers having a stiffening element as an integral part thereof. In practice, it was found that this expedient provides a more economical manner of producing the containers than that formerly practiced wherein individual preformed blanks having the stiffening attached thereto were used. In the illustrated embodiment of the invention, the stiffening material is of a size such that when folded about a forming block the stiffening sheet occurs on three sides of the container, the remaining side of the container being free of stiffening material.

Referring now to the drawings, 10 represents a forming block or mandrel comprising a part of a container forming machine indicated generally at 12 having a plurality of such forming blocks which are arranged to be intermittently moved to the various container forming stations of the machine. In general, in the operation of such machines, the leading end of a web 14 of sheet material is advanced into a position beneath the forming block 10 and severed to provide an individual sheet. The severed sheet is then folded about the forming block to form a tube, and the longitudinal marginal edges of the blank are adhesively secured together to provide a side seam. At a succeeding station of operation, portions of the tube extending beyond the end of the forming block are folded and adhesively secured together to provide a bottom closure for the container. The adhesive for sealing the side seam and the bottom closure is applied to the sheet material during the advance thereof and prior to advancing the sheet into operative relation to the forming block. Subsequently, the formed container is stripped from the forming block ready to be filled and top sealed.

In the illustrated embodiment of the invention the printed web 14 is continously withdrawn from a supply roll 16 by Web feeding mechanism including a continously rotated metering roll 18 which cooperates with a backing roll 20. Both the metering roll and the backing roll are provided with a rubber covered surface to prevent silpping of the web therebetween. The web is then advanced through adhesive applying mechanism indicated generally at 22; through take-up mechanism 24 which takes up the slack in the web between intermittent feeding operations; over a combining roll 66, and between the rolls of an intermittently operated feeding mechanism 25 comprising a lower driven feed roll 26 and a plurality of upper presser rolls 28. The intermittently operated feeding mechanism 25 is arranged to advance the leading end of the web 14 each cycle of operation into operative relation to be wrapped about its forming block, successive lengths being severed from the web by intermittently operated shearing mechanism indicated generally at 30. In general, the continously rotated metering roll 18 is rotated one revolution each cycle of operation, and feed correcting mechanism indicated generally at 32 is arranged to vary the feed in response to detecting means comprising a photosensitive control unit 34 disposed along the upper run of the web immediately preceding the intermittently operated feed rolls 26, 28. As illustrated in FIG. 4, the printed web 14 is provided with spaced registration marks 36, and in operation the photosensitive control unit 34 is arranged to be energized at a predetermined time each cycle during the continous movement of the web to detect the position of successive regislation marks, any deviation beyond a predetermined tolerance causing actuation of the detecting unit to effect operation of the correcting mechanism. It will be understood that the intermittently operated feed rolls 26, 28 operate to advance the slack in the web each feeding cycle and that the rolls will slip relative to the web when the web becomes taut so as to compensate for any variation in the length of web advanced by the feed rolls 18, 20 each cycle of operation.

The continuously rotated metering roll 18 is fast on a shaft 40 mounted in a racket 42 secured to the machine frame and is arranged to be rotated by a chain and sprocket drive 44 from a cam shaft 46 which in turn is driven through a gear train 47 from a main cam shaft 48 forming a part of the container forming machine. The backing roll 20 is connected to rotate with the metering roll 18 by spur gears 50, 52.

The adhesive applying mechanism 22 is driven from the cam shaft 46 through a chain and sprocket drive 54 and is arranged to apply strips of adhesive to selected areas of the web as it passes over a guide roll 56 which cooperates with a segmental adhesive applying roll 58-. The web is then passed under a guide roll 60 and then extends upwardly under a take-up roll 64 and over a combining roll 66 before passing between the intermittently operated feed roll 26 and its cooperating presser rolls 28. The presser rols 28 are carried by arms 68 mounted on a rocker shaft 70 supported in the machine frame, each presser roll being resiliently urged into engagement with the feed roll 26. The combining roll 66 forms a part of the mechanism for combining a stiffening sheet with the web as will be herinafter described.

The take-up roll 64 is carried by spaced curved arms 74 pivotally mounted at 76 and is urged to rock in a counterclockwise direction, viewing FIG. 1, by springs 78 to take up the slack in the web between intermittent feeding operations of the feed roll 26. The feed roll 26 is arranged to be intermittently rotated by connections from the cam shaft 48 through mechanism including a gear and rack connection 80, the rack being adjustably connected at its lower end to a slotted cam lever 82 pivotally mounted at 84. The lever 82 is provided with a cam roll 86 which cooperates with a cam 88 fast on the cam shaft 48. The rack gear 90 is mounted on a shaft 91 and forms part of an overrunning clutch 94, the driven portion of the clutch being keyed to the shaft 91. The feed roll shaft 92 is driven from the shaft 91 through a train of gears indicated at 93. During the downward stroke of the rack, the clutch is engaged to rotate the feed roll 26, and during the upward stroke of the rack, the clutch is disengaged leaving the gear 90 free to rotate in a reverse direction. In operation, the intermittently operated feed r9 1 26 advan s a l f the slack port on of he W b to render the web taut at which time the arms 74 of the slack take-up mechanism 24 engage adjustable stops 75 attached to the machine frame.

The shearing mechanism 30 includes a stationary shear blade 96 and a cooperating movable blade 98 arranged to be vertically reciprocated through cam operated linkage indicated generally at 100. The severed sheet 17 advanced into operative relation to be wrapped about the forming block 10 is arranged to be folded about the block by mechanism including vertcially reciprocable folding plates 104 also arranged to be actuated through cam operated linkage indicated generally at 106.

The metering roll 18 forms a part of the mechanism for controlling the feed of the web to effect registration of successive printed sections of the web with relation to the container forming mechanism, as fully illustrated and described in my copending application. Ser. No. 491,989, filed Oct. 1, 1965, now Patent No. 3,388,845, such mechanism including provision for varying the linear advance of the web during the continous movement thereof to compensate for any variations in the printed web. In order to fully understand the present invention, such mechanism will now be briefly described, reference being made to said copending application for a more complete description thereof. In operation, the metering roll 18 is continously rotated one revolution per cycle, the roll being of a circumference substantially less than the nominal length of successive printed sections of the web, and provision is made for rotating the roll 18 a further distance each cycle to advance successive sheets an additional length so as to obtain a total advance each cycle of a length slightly less than the nominal length of the sheet. The mechanism includes an overrunning clutch 112 mounted on the shaft 40, the driving member of which is connected to the chain and sprocket drive 44, the driven member being fast on the shaft 40, the clutch being arranged to positively rotate the metering roll through one revolution each cycle and to permit further feeding movement in the direction of advance of the web each cycle at which time the clutch is momentarily disengaged.

The means for effecting such further advance each cycle includes a second overrunning clutch 114, the driven member of which is fast on the shaft 40 and the driving member of which is provided with a radially extended arm connected by cam operated linkage indicated generally at 121 arranged to effect rocking of the arm each cycle.

The means for effecting a correcting stroke to further advance the web an additional increment in response to the photosensitive control unit 34 Comprises a third overrunning clutch similar to the clutch 114 and which is also provided with a driven member fast on the shaft 40 and driving member provided with a radially extended arm 146 connected to cam operated linkage indicated generally at 147. The overrunning clutch 140 is arranged to be engaged to effect an overfeed of the web 14 in response to the photoelectric control mechanism 34 when it detects a deviation from a maximum tolerance, and in order to prevent operation of clutch 140 until such time, latching mechanism indicated generally at 164 is provided to render the cam operated linkage inoperative until a deviation is detected, whereupon the latch mechanism is released.

The photoelectric control unit 34 is arranged to intercept spaced registration marks 36 on the web at a predetermined time in each cycle of operation, operation of the unit being initiated by a change of intensity of light reaching the unit. Entrance of a registration mark into the scanning area causes a change in phototube current which produces a signal to be impressed upon an amplifier circuit to close a relay not shown. The relay controls a solenoid valve for releasing the latching mechanism to permit operation of the linkage for rocking the clutch 140 to effect a corrective or overfeeding stroke. In practice, nor-. 1 6. underte d ng Of the Web will cause the spaced regis:

tration marks to lag so as to effect a gradual and cumulative lag relative to the photosensitive unit until a point is reached Where the unit is intercepted by the leading edge of a rapidly passing registration mark.

From the description thus far, it will be seen that the flexible container forming web 14 is continuously withdrawn from the supply roll 16 by the metering roll 18, and the leading end of the web is intermittently advanced one container forming length each cycle of operation by the feed rolls 26, 28, the material accumulated during the idle period of the intermittent feed mechanism 25 being maintained in a taut condition by the takeup mechanism 24. The leading end of the web 14 advanced into operative relation to be wrapped around the forming block is severed by the shearing mechanism 30 when the web is at rest and the feed rolls 26, 28 are idle.

In accordance with the present invention, provision is made for combining with successive container forming lengths or printed sections 17 of the web 14 a sheet of stiffening material, such as a sheet of cardboard 200 during the operation of the machine. In general, the combining mechanism indicated generally at 202 is arranged to advance a web of cardboard stiffening material to present the leading end thereof into registered position in engagement with the upper adhesively coated face of the flexible web 14 during a time when the web 14 is at rest whereupon the cardboard web is severed by shearing mechanism 204 to provide the stiffening sheet 200. The flexible sheet 14 is then intermittently advanced one container forming length at which time the cardboard sheet is carried along therewith and pressed into adhesive engagement with the flexible web. During the following cycle of operation, the leading end of the composite web is advanced into operative relation beneath a forming block and severed to be wrapped about the forming block to produce the container as described.

As herein illustrated, a web of cardboard stiffening material 206 of suitable width is continuously withdrawn from a supply roll 208 by web withdrawing mechanism including upper and lower feed rolls 210, 212. The upper feed roll is rotated by a chain and sprocket drive 214 from the adhesive applying roll shaft 216, and the lower feed roll 212 is geared to the upper feed roll. From the withdrawing rolls the Web 206 extends over an idler roll 218 mounted for rotation on a shaft 220 and over a take-up roll 222 arranged to take up the slack in the web between intermittent advancing movements thereof. The take-up roll 222 is carried by spaced arms 224 fast on the shaft 220 and is urged to rock in a direction to take up the slack in the web by a spring 226 connected between an arm 228 also fast on the shaft 220 and a stud attached to the machine frame. The web 206 then passes under an idler roll 230 and between the rolls of an intermittently operated feeding mechanism 232 comprising a lower driven feed roll 234 and cooperating upper rolls 236. The upper rolls 236 are carried by spaced arms 238 mounted on a rocker shaft 240 supported in the machine frame, each roll 236 being resiliently urged into engagement with the driven roll 234.

The driven roll 234 is arranged to be intermittently rotated by a gear and rack mechanism, the rack 242 being connected at its lower end to a crank 244 fast on the cam shaft 46. The rack gear 246 is mounted on a shaft 248 and forms part of a clutch 250, the driven portion of the clutch being keyed to the shaft 248. The clutch 250 is of the type which is engaged in driving relation with the shaft 248 during the downward stroke of the rack 242 to effect rotation of the feed roll 234, and which is disengaged during the upward stroke of the rack leaving the gear free to rotate in a reverse direction. In operation, the intermittently operated feed roll 234 advances all of the slack portion of the cardboard web to render the web taut at which time the arms 224 of the take-up mechanism engage suitable stops. It will be understood that the feed roll 234 is arranged to advance a predetermined length of cardboard each cycle of operation of the machine to present the leading end ofvthe web 206 onto the upper face of the flexible web 14 and between the combining roll 66 and a cooperating pressure applying roll 252 whereupon the cardboard Web is severed by the shearing mechanism 204.

The shearing mechanism 204 includes a stationary shear blade 254 and a cooperating movable blade 256 arranged to be vertically reciprocated through cam operated linkage including an arm 258 fast on a shaft 260 and which is connected at its outer end to the movable blade 256. A second arm 262 fast on the shaft 260 is connected by a link 264 to a cam lever 266 pivotally mounted on a shaft 268. The lever 266 is provided with a roller 270 for cooperation with a cam 272 fast on the cam shaft 46.

As herein illustrated, the combining roll 66 is fast on a shaft 274 which is connected by a chain and sprocket drive 276 to the intermittently operated shaft 92 on which the feed roll 26 is mounted. Thus, in operation, the combining roll is intermitently rotated at the same time as the feed roll 26. The pressure applying roll 252 is mounted to be rocked into and out of operative engagement with the combining roll66 and, in operation, the roll 252 is rocked to its raised position out of cooperating engagement with the combining roll 66 durin the time when the leading end .of the cardboard web 206 is advanced on top of the flexible web 14. In operation, the leading end of the cardboard web comes to rest in registered position with respect to a container forming section 17 of the flexible web 14 whereupon the cardboard web is severed. Thereafter, the web 14 with its cardboard sheet 200 is intermittently advanced by the feed mechanism 25 and its associated combining roll 66 and, simultaneously therewith, the pressure applying roll 252 is lowered into pressing engagement with the cardboard sheet so that during the advance of the material the cardboard sheet is pressed into engagement with the adhesively coated areas of the flexible web 14 to secure the sheet 200 to its container forming section 17.

As herein shown, the pressure applying roll 252 is carried by an arm 280 fast on a shaft 282 journaled in a bracket 284 attached to the machine frame. A second arm 286 also fast on the shaft 282 is connected by a yieldable link 288 to a cam lever 290 pivotally mounted at 292. The cam lever carries a roller 294 for cooperation with a cam 296 fast on the cam shaft 46. In operation, the pressure applying roll 252 is positively rocked upwardly by the cam operated linkage described, and upon downward rocking, the roll is resiliently urged into cooperating engagement with the composite web and the combining roll 66 by virtue of the yieldable link 288.

In operation, after the stiffening material is advanced into registered relation to a container forming section of the web and severed to form a sheet 200, the web 14 is advanced one container forming section along the upper run during which time a preceding container forming section previously supplied with a cardboard sheet is advanced into operative relation to the forming block 10 and severed to be wrapped about its forming block. Thus, a container forming section provided with a stiffening sheet during one cycle of operation is advanced into operative relation to its forming block during a succeeding cycle of operation.

From the above description it will be seen that the present container forming machine provides novel mechanism for attaching successive sheets of stiffening material in registered relation to successive container forming sections of the container forming material and that successive container forming sections, such as printed sections, with the stiffening material attached are advanced into operative relation to successive forming blocks to be severed and wrapped about the blocks to form containers having a stiffening sheet extending around three sides of the container as illustrated in FIG. 5.

Having thus described the invention, what is claimed is:

1. In a container forming machine of the character described, in combination, means for intermittently advancing successive container forming sections of a continuous flexible web of container forming material having adhesive applied to selected areas thereof, means for intermittently advancing the leading end of a predetermined length of a continuous web of stiffening material into engagement with the upper surface of a container forming section during the idle period of the flexible web, a pair .of combining rolls including a driven roll over which said flexible web is guided and a presser roll mounted to rock into and out of cooperating pressing engagement with said driven roll, means for severing the trailing end of said length of stiffening material to provide a sheet thereof, and means for rocking said presser roll into engagement with the leading end of said sheet to adhesively secure the sheet to its container forming section during the intermittent advance of the web.

2. In a container forming machine of the character described, in combination, means for intermittently advancing successive container forming sections of a continuous flexible web having adhesive applied to selected areas thereof into operative position to a forming block where it is adapted to be severed and wrapped about the forming block to produce a container, means for intermittently advancing a predetermined length of a continuous web of stiffening material into engagement with the upper surface of the flexible web in registered relation to a container forming section during the idle period of the latter, a pair of cmobining rOlls including a driven roll over which said flexible web is guided, and a presser roll mounted to rock into and out of cooperating pressing engagement with said driven roll, means for severing the trailing end of said predetermined length of stiffening material from its web, and means for rocking said presser roll into engagement with the leading end of said stiffening material for pressing the stiffening material into engagement with the adhesive coated areas of the flexible web during the intermitent advance thereof.

3. A container forming machine as defined in claim 2 wherein the means for intermittently advancing the flexible web is arranged to cause the flexible web to come to rest in a predetermined position relative to the length of advance of the stiffening material to present the leading end of the stiffening material in a predetermined registered position with relation to its container forming section.

4. A container forming machine as defined in claim 2 wherein the means for intermittently advancing the flexible web has provision for varying the length of advance of successive printed sections to compensate for any slight variations in successive lengths.

5. In a container forming machine of the character described, in combination, means for intermittently advancing successive container forming lengths of a flexible web of container forming material having adhesive applied to selected areas thereof into operative position to a forming block where it is adapted to be severed and wrapped about the forming block to produce a container, means for applying a sheet of stiffening material in predetermined registered relation to successive container forming lengths comprising means for continuously withdrawing a web of stiffening material from a supply thereof, means for intermitently advancing the leading end of the stiffening web into engagement with a container forming length during the idle period of the flexible web, means for taking up the slack in the stiffening web during the idle period of the intermitent advancing means, a pair of combining rolls including a driven roll over which said flexible web is guided, and a presser roll mounted to rock into and out of cooperating pressing engagement with said driven roll, means for severing the trailing end of the stiffening web after the leading end has been advanced into engagement with the flexible web to provide a sheet of stiffening material, and means for rocking said presser roll into engagement with the leading end of said stiffening material for pressing the sheet into engagement with the adhesive coated areas of the flexible web during the intermittent advance thereof.

6. A container forming machine as defined in claim 5 wherein the flexible Web advancing means includes means for continuously withdrawing container forming material from a supply thereof, means for applying adhesive to selected areas of successive container forming lengths during the continuous advance of the flexible web, and means for taking up the slack in the flexible web during the idle period of the intermittent advance of the same.

7. A container forming machine as defined in claim 6 wherein the flexible web comprises a printed web defining successive container forming sections, and wherein the web withdrawing means includes a metering roll arranged to withdraw a container forming length of the flexible web each cycle of operation, and control means adapted to vary the rotation of the metering roll in accordance with variations in the length of said printed container forming sections.

References Cited UNITED STATES PATENTS 1,627,811 5/1927 Smith 156-569 XR 2,332,101 10/1943 Mancuso 156199 XR 2,970,634 2/1961 Hantscho 156-202 2,998,760 9/1961 Allen 226156 XR 3,112,055 11/1963 Hartley 226156 XR 3,388,845 6/1968 Scully 22628 HAROLD ANSHER, Primary Examiner M. E. MCCAMISH, Assistant Examiner US. Cl. X.R. 

